Patch repair and texturing of wall construction surfaces kit

ABSTRACT

A patch for repairing a hole or a scrape on a perforated or scraped surface has a patching compound of a semi-fluid consistency that is stabilized with a mesh, such that the patching compound and mesh can be applied to a surface in a thin coat and can adhere and dry in a relatively short time. A package encloses the patching compound, and mesh is sized to approximate the package. Although the package can be any shape, one embodiment of the package has a rectangular top and bottom with side and end edges, the edges of one rectangle being connected to the edges of the other rectangle; the package including a packaging material which 1) is malleable permitting the application of pressure to create texture in the patching compound, and 2) retains the moisture of the enclosed patching compound. The package has at least one seal to connect the edges of the package to enclose the patching compound and mesh. Also disclosed are methods for patching and forming textured surfaces.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of prior application Ser. No. 11/562,407, filed Nov. 21, 2006, which is incorporated by reference in its entirety.

TECHNICAL FIELD

This invention is in the field of construction, specifically materials and methods for texturing surfaces and repairing holes, punctures, cut-outs, dents, imperfections, cracks, or scrapes on walls composed of plaster, drywall, sheetrock, stucco and a variety of surfaces, such as insulation, metal, and other materials.

BACKGROUND

Construction and decorating are increasingly becoming very popular for the amateur do-it-yourselfer. Among the biggest problems of the weekend do-it-yourselfer are the following: 1) making a mess requiring lengthy clean up; 2) failing to purchase all necessary materials and tools for the project, necessitating one or more returns to the store; 3) failing to complete the project in the brief discretionary or leisure time available for the project; and 4) buying excess amounts of products intended for much larger projects.

One of the more difficult challenges for the amateur to conquer is wall repair. There exist a number of products for this task, such as containers of joint compound and a variety of spreaders. One attempt at a wall repair kit included a bucket, pint container of repair mix, tube of spackle, mesh tape, sanding supplies and other tools, weighing 2.5 pounds. However, the amateur or professional decorator wants to accomplish the job in a single step without the mess, a need which is currently not satisfied.

A job beyond the talent and experience of all but the most committed repairman is texturing walls. There are available shaggy paint rollers which improve the visual appearance of the completed repair. Prior to the instant invention, there has been no way to easily and conveniently repair a wall which has been previously textured. Reapplying a shaggy paint roller often leads to excessive accumulation of texturing materials and paint, resulting in an undesirable result and unsightly, unacceptable repair.

What is needed is a one-step, ready-to-apply wall repair kit, which is readily applied to a flat or textured wall.

SUMMARY OF THE INVENTION

In one embodiment, there is provided a patch for repairing a hole or a scrape on a surface that contains a patching compound of a semi-fluid consistency, such that the compound can be applied to a surface in a thin coat and can adhere, seal and dry in a relatively short time. Also provided is a mesh which helps support the patching compound. A package encloses the patching compound, the package having at least two surfaces and a plurality of edges, the edges of one surface being connected to the edges of the other surface; the package including a packaging material which 1) is malleable permitting the application of pressure to create texture in the patching compound, and 2) retains the moisture of the enclosed patching compound. The package has at least one seal to connect the edges of the package to enclose the patching compound and mesh. Such a patch is also provided in a kit with instructions.

In another embodiment, there is a method for patching a surface that utilizes the afore-mentioned patch. The steps include the steps of removing seals from three of the edges of the patch packaging, pulling two opposite unsealed edges of the package to spread out the patch compound, applying the patching compound to the surface, applying a sideways motion to the patch package to affix the patching compound to the surface, and peeling the patch package away from the patching compound, thereby covering the surface with a patch.

In another embodiment, there is provided a method for texturing surfaces that utilizes the afore-mentioned patch and has the steps of removing seals from the edges of the patch packaging, opening two opposite unsealed edges of the package to spread out the patching compound, applying the patching compound in the surface, applying a sideways motion to the patch package to affix the patch compound to the surface, and peeling the patch package away from the patching compound.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features, advantages and objects of the invention, as well as others which will become apparent, are attained and can be understood in more detail, more particular description of the invention briefly summarized above may be had by reference to the embodiment thereof which is illustrated in the appended drawings, which drawings form a part of this specification. It is to be noted, however, that the drawings illustrate only a preferred embodiment of the invention and is therefore not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.

FIG. 1 is a perspective schematic view of a patch, showing the sealed edges and the central area containing the patching compound, as well as tear lines (dotted lines).

FIG. 2 is a perspective schematic view of a patch, showing the mesh in the patching compound.

DETAILED DESCRIPTION OF THE INVENTION

The invention is a disposable, self-contained, one-step, ready-to-apply, wall-repair kit and method for use wherever wall repair may be needed. The kit can be used to make patches or can be placed over patches to give a smooth or textured surface. The kit can be used alone on small defects and punctures, such as holes caused by nails, picture hanging devices, mollies, and other wall fastening devices. In addition, the invention can be used to cover and provide texture to larger surface areas and defects, wherein underlying patching may be required as an appropriate base for use of the kit to provide the desired final flat or textured surface. The invention can be provided in various sizes up to and including wall size.

The major component of the kit is a malleable, plastic package of patching compound or joint compound (FIG. 1). The package 10 is preferably relatively flat and can be any shape but is preferably square, rectangular or circular. The patching compound 20 can be made from joint compound or other suitable material and is formulated to be both soft when applied for easy texturing or flattening and for rapid adherence and drying when applied, so that the finished repair can be promptly painted or otherwise finished.

The patching compound is a ready-to-use material which requires no mixing or other preparation. The patching compound has a semi-fluid consistency such that the compound can be applied to a surface in a thin coat and can adhere and dry in a relatively short time. The patch is applied by manipulating the plastic cover of the package, so as to minimize or eliminate messy contact with hands, clothing, or surrounding surfaces or objects. Once the patching compound is applied, the plastic cover is peeled off the patch and is folded upon itself to keep the mess to an absolute minimum. This feature has the advantages of no mixing or other preparation of the patching compound and eliminates or minimizes mess.

The prototype repair kits have been manufactured by hand to the inventor's specifications. Squares, rectangles or other shapes of plastic sheeting were cut to the desired size and laid on a flat surface. A quantity of diluted joint compound was placed on one side of the sheet and a mesh (discussed below) was applied to the patching compound. The plastic sheet was folded in half over the joint compound. The package 10 was next pressed flat until the edge of the patching material almost reached the edges 30 of the sheet. The edges 30 of the sheet were sealed shut 40 with heat. Optionally the package 10 has tear strips 50 pressed into the periphery. For these prototype units, the plastic was not preprinted with instructions for use or any other information, such as the included plastic utility knife.

FIG. 2 shows another embodiment of the wall-repair package in FIG. 1. In addition to the features mentioned above, this embodiment also has a mesh 60 in the patching compound 20 compartment. The mesh is a pliant material that bends with the package and helps support the patching compound as it is being placed. The mesh is a water resistant material (for use with water-based patching compounds) which is compatible with the patching compound. It can be made from a number of different compounds, including but not limited to nylon, plastic, paper or basically any woven or nonwoven material. The mesh 60 is shown with regular spaces between its fibers. However, the mesh can have irregular spaces or no spaces between fibers. For purposes of illustration, the mesh is shown as black. However, it can be any color or uncolored. The mesh fibers can be translucent or transparent. Because one embodiment of the wall-repair package is intended to be opened like a book to display and place the patch on the wall, this embodiment incorporates two layers of the mesh that separate as the front and back of the package are separated.

To those skilled in the art, a variety of alterations to the non-commercial manufacture of the repair kits can be deduced. The repair kits can be made in any number of geometric configurations, filled with various types of patching compounds (including, but not limited to, joint compound, plaster, and SPACKLE surfacing compound), filled with various quantities of patching compound, compressed and flattened to various thicknesses. The thickness of the packet is preferably less than one inch, preferably less one half inch and more preferably less than about one fourth of an inch. The plastic can be folded in half or other proportions over the patching compound to form a container. To close the package layers of plastic, heat sealing, hot or cold glue, or other adhesives also can be used, such that such sealing technique provides an airtight seal to prevent the patching compound from drying out. Although the plastic container is preferably clear, it can be translucent or tinted and pre-printed with directions. Alternately, plastic container may be replaced by polyvinyl chloride, polyolefin, coated paper or plastic or another pliable plastic or even with another pliable, inexpensive material that does not chemically or physically react with the patching compound and is compatible with the sealing technique used. When the container is sealed, it optionally will have tear strips 50 pressed into the periphery.

The patch kit can be marketed in its manufactured, flexible form or can be placed in any number and variety of sturdy storage, shipping, handling and/or display containers, including but not limited to a cardboard slot. Such external containers for the repair kit can be stamped, preprinted with ink, silk screened or covered with other suitable means known to those skilled in the art. Alternately, the plastic package of the repair kit itself can likewise be printed or silk screened with directions, contents, source and other information. The package is preferably relatively flat, so that it can be shipped economically and stored flat. The package also permits the decorator to customize the texture of the repair by applying manual pressure in different amounts and to different locations on the patch covered by the plastic. The harder the pressure the decorator applies, the deeper is the texturing. The package is preferably clear or translucent to permit user to see the final effect on the covered surface before removing the patch to optimize the final visual result.

Those skilled in the art realize that the patch package can be manufactured per specifications on an assembly line or by way of a specially-tooled machine which can apply patching compound and mesh and seal the plastic packaging along with easy-use tear strips within the same process. Continuous rolls of plastic can be used and can be pre-printed, as the stamping machine provides uniformly sized patch packages. Thusly manufactured patch packages can then be placed in individual sleeves or in multiple-package shipping containers. The applicator(s) can be provided in the sleeved kits for hanging or separately in a retail point-of-purchase product container.

The patching compound can be applied to a variety of materials, including but not limited to, drywall or sheet rock, painted and unpainted surfaces, insulation, and metal. Other possible surfaces for patching are possible and can be readily determined by applying a corner of the patching material to the surface to determine adherence. With the water-based patching material disclosed above, the patching material may not adhere permanently to a surface which collects moisture. In that case, a non-water based patching compound and compatible mesh are preferred.

The method for patching begins with obtaining the patch kit, or at least the flat packet containing the patching material. The amateur or professional decorator obtains, for example, a rectangular package such as is shown in FIG. 2 and cuts open three sealed sides of the flat packet. Optionally the sealed sides are imprinted with cutting marks or easy-tear strips. Then the user opens up the packet (like opening a book away from the reader) with the patching compound/mesh side facing the surface and the plastic side facing the user. The amateur or professional decorator applies the patching compound directly to the desired area by pressing down firmly. At this time, the decorator can optionally form a texture by applying different pressures to different areas of the patching compound. Then the amateur or professional decorator slowly pulls the edges from side to side or up and down to further cause the compound to adhere to the surface. Preferably, the amateur or decorator drags the plastic edges approximately two inches in each direction for maximum adhesion to the surface. Next, the decorator pulls one side of the plastic away from the compound, peels off the rest and discards the plastic. The removal of the plastic also leaves an uneven, textured surface. If the decorator chooses to adjust the surface effect, the amateur or decorator can use the optional spreading tool, or another handy tool such as a putty knife. So adjusting the surface should be done lightly; otherwise, the texture application may become too thin and require a new application. An important advantage of this method over current methods is that it is a one-time, single-use disposable application for small repairs.

This kit and method can be sized for small texturizing projects, such as holes, punctures, cut-outs, dents, imperfections, cracks, or scrapes of walls composed of plaster, drywall, sheetrock, stucco and a variety of surfaces. Insulation, metal, and certain other materials. The kit with enlarged patching package also can be used for large projects.

The invention has several advantages. The product is easy-to-use for any level of user knowledge or skill. This is a single-use, readily disposable product, so there is no issue of trying to store left-over product, which would not be useful in the future. The product and method are very easy and straightforward and can be completed quickly with a minimum of user time.

While the invention has been shown in several embodiments, it should be apparent that it is not limited to those embodiments but is susceptible to various changes without departing from the scope of the invention. 

1. A patch for repairing a hole or a scrape on a perforated or scraped surface, comprises a. a patching compound of a semi-fluid consistency, such that the compound can be applied to a surface in a thin coat and can adhere and dry in a relatively short time; b. a mesh whose dimensions approximate the dimensions of a package; c. the package enclosing the patching compound and the mesh, said package having two malleable surfaces and a plurality of edges; the package comprising a packaging material which i. is malleable permitting the application of pressure to create texture in the patching compound, and ii. retains the moisture of the enclosed patching compound; and d. at least one seal to connect the edges of the package to enclose the patching compound and mesh.
 2. The patch of claim 1, wherein the patching compound is water based.
 3. The patch of claim 1, wherein the patching compound is based on a known joint or filling compound.
 4. The patch of claim 1, wherein the mesh extends almost to the seal on the sides.
 5. The patch of claim 1, wherein the mesh extends into the seal on the sides.
 6. The patch of claim 1, wherein the package comprises basically a rectangular top and bottom with side and end edges, the edges of one rectangle being connected to the edges of the other rectangle.
 7. The patch of claim 1, wherein the mesh comprises regular, irregular or no visible spaces between a plurality of threads.
 8. The patch of claim 1, wherein the seal is formed by heat or glue.
 9. A kit for patching a hole or a scrape on a surface, the kit comprising the patch of claim 1 and directions for mounting the patch on a surface.
 10. The kit of claim 6, wherein the kit further comprises a spreading tool.
 11. The kit of claim 6, wherein the kit further comprises a box to contain the patch and optionally the spreading tool.
 12. A method for patching a perforated or scratched surface, the method comprising the steps of a. obtaining the patch kit of claim 9: b. removing at least one seal from at least one edge of the patch packaging; c. pulling two unsealed edges of the package to spread out the patching compound; d. applying the patching compound to the surface; e. applying a sideways motion to the patch package to affix the patching compound to the surface; and f. peeling the patch package away from the patching compound, thereby covering the perforated or scratched surface with a patch.
 13. A method of texturing a surface, the method comprising the steps of a. obtaining the patch kit of claim 6; b. removing seals from the edges of the patch packaging; c. opening two opposite unsealed edges of the package to spread out the patching compound; d. applying the patching compound to the surface; e. applying a sideways motion to the patch package to affix the patch to the surface; and f. peeling the patch package away from the patching compound.
 14. The method of claim 13, wherein step d further includes pressing the patching compound with different force in different areas to design the texture.
 15. The method of claim 13, wherein the seals are removed with a sharp tool.
 16. The method of claim 13, comprising a further step of g. adjusting the texture of the applied patching compound with a spreading tool. 